Transformation Outcomes
Case Studies
Real outcomes from the shop floor, with clear challenges, implementation details, and measurable business impact.
20
Published Case Studies
20
Industries Covered
80
Result Metrics Captured
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Showing 20 case studies
Solar PV Manufacturing
37% More Modules a Day, From the Same Plant
A Rs 2,500+ crore solar PV manufacturer lifted finished output from 1,404 to 1,923 modules per day in six months by recovering hidden losses at the stringer constraint.
Composite Pipe Manufacturing
58% More Output from the Same Winding Lines
A composite pipe manufacturer improved output by 58% and OEE by 25% by attacking changeover loss on helical filament winding lines.
Packaging and Label Printing
OEE More Than Doubled in Twelve Months
A national printing and packaging operation improved OEE by 123% in 12 months while reducing changeover time by 47% and wastage by 36.6%.
Advanced Materials
Flow Revealed Capacity the Batch Was Hiding
A sports-equipment manufacturer improved productivity by 269%, increased output 24%, and reduced throughput time 40% by moving from batch to flow.
Iron and Steel
Rs 15.24 Crore a Year, Found in Cost No One Was Watching
A Rs 1,500+ crore metals producer reduced conversion cost and consumable inventory burden, delivering about Rs 15.24 crore annual savings.
Food Processing
51 Roles Redeployed, Without Losing a Unit of Output
A bakery operation rebalanced four departments and safely redeployed 51 roles while fully holding output.
Textile
Rs 1.67 Crore a Year, from Staffing Decisions Made on Data
A knitted-fabric and garment operation reduced manpower cost by 11% over 15 months, delivering around Rs 1.67 crore annual savings.
Locks Manufacturing and Ecommerce
197% More Storage, in the Same Four Walls
A locks manufacturer unlocked 197% additional storage capacity by redesigning vertically and aligning WMS logic with new flow.
Industrial Packaging
Less Raw-Material Space, More Boxes per Shift
A Fortune 1000 packaging operation cut raw-material storage from 50,000 to 38,000 sq ft while output increased from 12 to 25 boxes per shift.
Ceramic Tiles
Two-Thirds Faster Turnaround, Same Building
A ceramic tiles warehouse cut turnaround time by 68% and increased storage capacity by 43% by reducing handling and improving storage logic.
Fashion Jewellery
Picking Productivity More Than Doubled
A jewellery distribution operation serving 68 stores and ecommerce improved picking from 5.6 to 12.2 items/min and cut touchpoints from 17 to 10.
D2C Fashion
Carton-to-Rack, from 6.4 Days to 1.2
A D2C fashion brand integrated inbound and fulfilment flow, reducing carton-to-rack from 6.4 days to 1.2 and overall order processing time by 81%.
Electrical Products Manufacturing
When Suppliers Miss, the Plant Pays for It
A leading electrical products manufacturer improved vendor OTIF from 48% to 64% and order fill rate from 93.7% to 96.1% through supplier visibility and planning cadence.
Artificial Leather
Rs 1.2 Crore a Year, Built Through Suppliers, Not Around Them
A large automotive and footwear supplier improved material availability and productivity through supplier development, delivering around Rs 1.2 crore annual savings.
Construction
Procurement Lead Time Cut 30%, Across Every Site
A construction organization moved from ad-hoc, site-by-site procurement to one visible workflow, reducing procurement lead time by 30%.
FMCG Manufacturing
27% Better OTIF, Measured Before It Was Fixed
An FMCG manufacturer improved OTIF by 27% after establishing structured OTIF measurement, ERP pipeline visibility, and root-cause corrective action loops.
Seasonal Retail
On-Time Fulfilment, from 82.3% to 96.5%
A seasonal demand network redesigned for peak behavior improved on-time fulfilment from 82.3% to 96.5% while reducing logistics cost.
Industrial Valve Manufacturing
A Facility Designed for 2.7X the Output
A valve manufacturer planned capacity from flow logic first, increasing planned output from 1,242 to 3,372 units/day before construction.
Packaging Manufacturing
A New Plant, Built Right the First Time and Commissioned on Schedule
A family-owned packaging exporter designed and commissioned a growth-ready greenfield facility on schedule, built exactly to drawing with no design change during construction.
Aluminium Rolling
40% Revenue Growth, from the Plant Already There
A large aluminium rolling operation improved flow, setup performance, and workforce deployment to unlock installed capacity and drive 40% revenue growth.